Re: Black Max this is a tough one???
I got vexed by a semi-bad stator once. Landlocked facility, ohms readings were not that far off spec and DVA readings cranking showed good. But it broke-down under real-world conditions. Customer couldn't get full speed. It ended-up being the stator, but it could've just as easily been a switchbox.
The stator has separate high and low speed windings to each of two switchboxes.
The switchboxes combine and convert the voltage from the stator to produce voltage to the coils.
If the stator has a partially failed winding, one switchbox doesn't get the necessary voltage to produce high-speed spark to up to three cylinders.
But if the portion of the switchbox that processes that voltage from the stator has a problem, then the fault lies with the switchbox.
I was always told that ohms specs were ballpark figures and this one was just barely outside of the ballpark. But enough to cause the problem. Replaced stator, problem solved. No guarantee it's your solution, however. It could still be a switchbox. (In the vast majority of stator failures, one or more winding(s) shows no resistance at all rather than slightly out of spec which was what did me in.)
Testing DVA output from the stator and resistance readings must be considered in tandem and I think that's where your answer lies.
If the repair facility is fortunate enough to be on-water, the problem can be seen with a timing light. Some cylinders would lose flash at high speed. If the switchboxes are swapped, the problem will travel with the switchbox. If not, the problem lies with the stator. (The stator leads would have to remain with the inside/outside switchboxes as would the coil leads. Your mechanic should understand this. One set has yellow tubes, the other set does not. Yellow-tube leads go to the outer switchbox. Feel free to print and share. I hope it helps, and I hope it's not as totally confusing as it was to me at first.)
